Method of making microtubes with axially variable geometries

ABSTRACT

In the present invention, a technique is described for manufacturing microtube devices which have peripheral geometries that are not uniform along the tube or device axis. These geometries may exist in only one location on the periphery of the microtube device or geometries may be repeated either uniformly or non-uniformly with micron or sub-micron precision along the tube or device axis. The preferred manufacturing process involves forming a complex mandrel, ie., (one, for example, that can not be formed by extrusion or pultrusion under constant processing conditions) and giving it at least one metallic and/or nonmetallic coating by any of a variety of techniques. The complex mandrel can then be removed by appropriate chemical or physical means that do not adversely affect the coating(s) desired for the wall. The result is a microtube structure having an axial profile duplicating that on the mandrel from which it was formed.

CROSS-REFERENCES TO RELATED PATENT APPLICATIONS

The present patent application is related to U.S. patent applicationSer. No. 08/472,574 now U.S. Pat. No. 6,059,001. Although the presentpatent application is not pending therefrom, it incorporates severalfeatures as shown and described therein.

STATEMENT OF GOVERNMENT INTEREST

The invention described herein may be manufactured and used by or forthe Government for governmental purposes without the payment of anyroyalty thereon.

BACKGROUND OF THE INVENTION

The present invention relates to machines, and, in particular, relatesto micromachines, and further, relates to free-standing microtubedevices.

In recent years there has been tremendous interest in miniaturizationdue to the high payoff involved. One area of current interest ismicroelectromechanical systems (MEMS) and the closely related fields ofmicro-fluidics and micro-optical systems. Presently, these technologiesinvolve micro-machining on a silicon chip to produce numerous types ofdevices, such as sensors, detectors, gears, engines, actuators, valves,pumps, motors, and mirrors on the micron scale. The first commercialproduct to arise from MEMS was the accelerometer manufactured as asensor for air-bag actuation. On the market today, there are alsomicro-fluidic devices, mechanical resonators, biosensors for glucose,and disposable blood pressure sensors that are inserted into the body.

The vast majority of microsystems are made almost exclusively on planarsurfaces using technology developed to fabricate integrated circuits.That is, the fabrication of these devices takes place on a wafer and thedevice is formed layer-by-layer with standard clean-room techniques thatinclude e-beam or photolithography, thin-film deposition, and wet or dryetching.

Although there have been numerous and very innovative successes usingthese silicon wafer-based technologies, there are some disadvantages.Since it requires the building-up of many layers of different materialsas well as surface and bulk micro-machining there are some verydifficult material science problems to solve. These include differentialetching and laying down one material without damaging a previous layer.In addition, there are the problems associated with interconnectinglayers in a chip with different functions. An example of this would be amicro-fluidic device in which there are both fluidic and electronicfunctions. Clearly, there are numerous materials' issues central to thistechnology.

In addition to these processing problems, there are other limitationsinherently associated with conventional lithographic techniques that arebased on planar silicon. For example, in some applications such as thosethat involve surface tension in fluidics, it is important to have acircular cross-section. However, it is impossible to make a perfectlyround tube or channel on a chip with current technology. Insteadchannels are made by etching a trench and then covering the trench witha plate. This process can only produce angled channels such as thosewith a square, rectangular, or triangular cross-section.

Thus, there exists a need for microtube devices not associated withplanar technology.

SUMMARY OF THE INVENTION

In the present invention, a technique is described for manufacturingmicrotube devices which have interior geometries that are not uniformalong the tube or device axis. These geometries may exist at only onelocation along the axis of the microtube device or specific geometriesmay be repeated either uniformly or non-uniformly with micron orsub-micron precision along the tube or device axis. The preferredmanufacturing process involves first forming a complex fiber mandrel.{In this application we define a complex fiber mandrel as one that cannot be formed by extrusion, pultrusion, spinning, stretching, or drawing(with or without a die) under uniform fabrication conditions that do notvary with time.} Once the complex fiber mandrel has been formed, it isgiven at least one metallic and/or nonmetallic coating by any of avariety of techniques. The complex fiber mandrel can then be removed byappropriate chemical or physical means that do not adversely affect thecoating(s) desired for the tube wall. This results in a microtubestructure having an interior axial profile duplicating the exteriorprofile on the mandrel from which it was formed. The microtubestructures of this application as well as the microtubes and microtubedevices of previous patents can stand alone or can be a component partof another device.

One group of techniques for forming a complex mandrel consists ofemploying non-uniform conditions while making fibers using techniquesnormally employed in the production of fibers. Another group oftechniques for forming the complex mandrel consists of adding materialto, removing material from, or redistributing material on a fiber coreat precise locations on the periphery of the fiber core, which consistsof one or more fibers held rigid during processing. The term fiber asused here is used in its most general sense and refers to natural orsynthetic filaments of any material such as polymer, cellulose, glass,ceramic or metal. In the case of material addition to the fiber core,the added material may be of the same composition as the fiber core orof a different composition. An additional type of technique for forminga complex mandrel involves wrapping at least one threadlike componentaround a core. These overwrap threadlike components may be of the samecomposition as the core or they may be of a different composition. Inthe simplest example both the core and the overwrapped threadlikecomponent are as-extruded or as-drawn fibers. However, it should benoted that in some applications the core can also be a macroscopicobject with a threadlike component, microtube, or microtube devicewrapped around it.

To form a complex mandrel by the wrapping of one fiber around anotherinvolves drawing a single core fiber (or bundle of core fibers) througha confining orifice. The overall fiber core is held with minimalconstraint (typically by friction), so that no breakage takes place asit is drawn through the orifice. However, enough constraint exists sothat torque applied tangentially by an overwrapping fiber (or fibers) asit is being wound around the fiber core does not cause the one or morecore fibers to slip in the direction of applied torque. Moreover, theoverwrapping one or more fibers must be wound sufficiently close to theconstraining orifice that twisting of the core one or more fibers in thedirection of torque is minimized to such an extent that unwinding, or“backlash” does not occur when constraining forces are removed at theend of winding. Also, sufficient force must be exerted by theoverwrapping fiber to insure that it winds itself tightly around thefiber core, thereby precisely maintaining desired dimensions andgeometry. Finally, physical properties of the overwrapping fiber must besuch that torsional stresses remaining after winding are insufficient todisrupt configuration of the formed mandrel when constraining forces ofthe winder are released. Polyetherimide has been found to be anexcellent overwrapping fiber in this respect.

Therefore, one object of the present invention is to provide severalmethods for making complex fiber mandrels.

Another object of the present invention is to provide aprecision-controlled adjustable-torque micro-winder able to wind one ormore micron-sized fibers around a core of a micro-object, macro-object,or at least one micro-sized fiber.

Another object of the present invention is to provide a method of makingmicrotube devices from complex mandrels.

Another object of the present invention is to provide a variety ofmicrotube devices.

These and many other objects and advantages of the present invention,will be readily apparent to one skilled in the pertinent art from thefollowing detailed description of a preferred embodiment of theinvention and the related drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a fiber wrapped around a core fiber.

FIG. 2 partially illustrates a device for winding a fiber about a corefiber.

FIG. 3 partially illustrates a device for winding a fiber about a corefiber using a positioner.

FIG. 4 is an axial view of the device of FIG. 3.

FIGS. 5A and 5B illustrate different methods of making structures withaxial repeat unit.

FIG. 6 illustrates a composite coil consisting of a coiled coated corefiber.

FIG. 7 illustrates a microtube coil.

FIG. 8A illustrates a side view of wrapped bellows.

FIG. 8B illustrates (by photo) wrapped bellows.

FIG. 9 illustrates a micro-threaded screw.

FIG. 10A illustrates a central microtube having a layer microtubewrapped about such.

FIG. 10B illustrates (by photo) a heat exchanger.

FIG. 11 illustrates a microtube threaded screw having a single channelwrapped thereabout and coated.

FIG. 12 illustrates a real circular bellows

FIG. 13A illustrates a square bellows.

FIG. 13B illustrates a square bellows with a twist.

FIG. 13C illustrates a circular bellows with a dove-tail end

FIG. 14 illustrates a linear micro-actuator.

FIG. 15 illustrates a micro-valve.

FIGS. 16A and 16B illustrate micro-fingers that are able to be pointed.

FIGS. 17A, 17B and 17C illustrate a bellows capable of bending motion.

FIGS. 18A through 18H illustrate the manufacture of devices having anannulus.

FIG. 19A illustrates a microscopic nozzle.

FIG. 19B illustrates the rocket nozzle for micro-thruster on a penny.

FIG. 19C illustrates a micro-camera bellows with a lens shade.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the present invention, a technique is described for manufacturingmicrotube devices which have interior geometries that are not uniformalong the tube or device axis. These geometries may exist at only onelocation along the axis of the microtube device or specific geometriesmay be repeated either uniformly or non-uniformly with micron orsub-micron precision along the tube or device axis. The preferredmanufacturing process involves first forming a complex fiber mandrel.{In this application we define a complex fiber mandrel as one that cannot be formed by extrusion, pultrusion, spinning, stretching, or drawing(with or without a die) under uniform fabrication conditions that do notvary with time.} Once the complex fiber mandrel has been formed, it isgiven at least one metallic and/or nonmetallic coating by any of avariety of techniques. The complex fiber mandrel can then be removed byappropriate chemical or physical means that do not adversely affect thecoating(s) desired for the tube wall. This results in a microtubestructure having an interior axial profile duplicating the exteriorprofile of the mandrel from which it was formed.

The term complex mandrel as used in this application is a general termused to describe at least one fiber or microscopic object of high aspectratio of length to diameter whose axial profile is not uniform. That is,there can exist protrusions, depressions, or changes in radialdimensions of any desired shape and location on the periphery of thecomplex mandrel. Thus, these complex mandrels, which have any desiredcross-sectional shape, can possess either a uniform, non-uniform, orrandom variation in thickness at any point along their axes. Complexmandrels consist of a core of at least one fiber or at least onemicroscopic object of high aspect ratio with a cross-sectional dimensionin the range of 1-1000 microns. When the axial profile varies due to achange in radius of the core, this type of mandrel is called a complexradial mandrel. If the axial geometry is modified by adding material ofdesired shape and height at predetermined locations on the periphery ofthe fiber core, the complex mandrel is called a complex augmentedmandrel. In contrast, a complex reduced mandrel is formed by selectivelyremoving material to a desired depth from the periphery of the fibercore at pre-determined locations. Movement of material on the fibersurface to produce the desired axial geometry is called a complexredistributed mandrel. Additionally, the axial geometry of a core can bemodified by overwrapping at least one threadlike component around thecore. The resulting complex mandrel is called a complex overwrappedmandrel. Finally, if more than one of these techniques is employedsequentially on any one mandrel, the resulting mandrel is referred to asa complex sequential mandrel.

As just mentioned, one technique for forming a complex mandrel consistsof changing the radial dimension along the axis of the fiber core. Thereare many ways to do this in either a random, uniform, or non-uniformfashion. For example, the radius of a fiber can be changed duringmanufacture by changing the manufacturing parameters as the fiber isbeing made. Taking melt spinning of fiber as an example, the radius ofthe fiber can be changed by varying one or more parameters such as, thetemperature of the melt, the pressure on the melt, the local fiberdensity, the tension on the fiber, the geometry of the spinnerette orthe geometry of the spinning process itself. With wet spinning, there isthe additional possibility of varying the composition of the fiber orthe solution. The change in the radius along the axis could be a singleevent or cyclic. In addition the change could be random, uniform, orvary in a predictable manner with location along the fiber axis.

The radius of a fiber or a coated fiber can also be changed after it hasbeen manufactured. For example, the radius of a hollow fiber can beincreased either randomly, uniformly, or non-uniformly at any desiredlocation(s) along the fiber axis using heat and pressure or acombination of these parameters. For example, using a combination ofheat and differential pressure (higher internally), the diameter of ahollow fiber that softens with temperature can be increased at theposition where heat is applied. Depending upon how uniform the heat anddifferential pressure are applied at each point along the axisstructures such as bubbles and tapers can be fabricated. In addition,the radius of a fiber can be decreased either randomly or uniformlyusing heat, tension, pressure or a combination of these parameters. Forexample, using a combination of heat and tension, the diameter of afiber that softens with temperature can be decreased. Depending upon howuniform the heat and tension are applied at each point along the fiberaxis a myriad of structure from tapers to teardrops can be fabricated.It should be noted that this is the only technique discussed in thisapplication where the length of the mandrel core changes. In addition,it should be noted that with these techniques that vary the radius alongthe axis, the radius around the axis at each position along the axis mayor may not be uniform depending upon how uniformly the heat, forexample, is applied.

Another technique for forming a complex mandrel consists of winding atleast one threadlike component with a cross-sectional dimension in therange of 1-1000 microns around a core. In one preferred embodiment ofthis technique discussed in the examples that follow, this core consistsof at least one fiber. However, it should be noted that the core canalso be any microscopic object of relatively high aspect ratio of lengthto diameter with a dimension in at least one direction of 1-1000microns. Likewise, in one preferred embodiment of this techniquediscussed in the examples that follow, the threadlike overwrappingcomponent consists of at least one fiber. However, it should be notedthat the threadlike component cab also be any microscopic object ofrelatively high aspect ratio with dimension in at least one direction of1-1000 microns.

In light of the foregoing discussion, it needs to be recognized thateither the core, the threadlike overwrapping component, or both canconsist of at least one axially uniform fiber, a microscopic object ofrelatively high aspect ratio, another complex mandrel, a coated complexmandrel, a complex mandrel from which the core, or mandrel and/or atleast one coating has been removed, or even a complex sequential mandrelthat has been previously manufactured.

In one preferred embodiment using a fiber as the core, the fiber isdrawn through a confining orifice in a precision-controlledadjustable-torque micro-winder. The fiber is held with minimalconstraint (typically by friction), so that no breakage takes place asit is drawn through the orifice. However, enough constraint exists sothat torque applied tangentially by another overwrapping fiber (orfibers) as it is being wound around the fiber core does not cause thecore fiber(s) to slip in the direction of applied torque. Moreover, theoverwrapping fiber must be wound sufficiently close to the constrainingorifice that twisting of the fiber core in the direction of torque isminimized to such an extent that unwinding, or “backlash” does not occurwhen constraining forces are removed at the end of winding. Also,sufficient force must be exerted by the overwrapping fiber to insurethat it winds itself tightly around the fiber core, thereby preciselymaintaining desired dimensions and geometry. Finally, physicalproperties of the overwrapping fiber must be such that torsionalstresses remaining after winding are insufficient to disruptconfiguration of the formed mandrel when constraining forces of thewinder are released. Polyetherimide has been found to be an excellentoverwrapping fiber.

In all areas of science and engineering, as miniaturization hasoccurred, some physical and chemical effects and parameters have eitherbecome dramatically elevated in importance or actually become thedominant variables. In a very real manner of speaking, new worlds areentered into, in which design considerations and forces that arenormally negligible in human-scale applications become essential tosuccessful utilization and application of the miniaturized technology.What makes the precision-controlled adjustable-torque micro-winder usedin this invention to make complex microtube mandrels uniquely differentfrom a much larger-scale winding apparatus is that it specificallyaddresses these micro-effects. In a larger macro-scale winder, overwraptorques due to fiber winding position and fiber physical properties areeither negligible because overwrap wires or cables are much smaller orweaker than the core, or the overwrapping process is madetorque-balanced with respect to the core by wrapping two or more wiresor cables simultaneously on the core from either multiple or simplyopposing directions, thereby eliminating any net torque in only onedirection on the core. This latter process usually requires that thecore remain stationary with the overwrapping wires or cables beingrotated about it in order to perform wrapping. In this winder, however,because of the micro-scale, the ability to precisely adjust and controlnet torque on the core by the at least one overwrapping fiber iscritical to successful fabrication of microdevices of the presentinvention.

Referring to FIG. 1, actual winding of the overwrapping fiber(s) 10around the fiber core 12 can be accomplished in numerous ways. The threemost useful are: (1) rotating the fiber core 12 as it is drawn throughthe orifice, while not allowing the overwrapping fiber to rotate, butonly to translate along its axis towards the fiber core under controlledtension; (2) holding the fiber core non-rotating as it is drawn throughthe orifice, and the overwrapping fiber wound around it under tension;and (3) rotating both core and overwrapping fiber either in the same oropposing directions during winding with the result being a braided orwoven overwrap.

Spacing of the wound overwrapping fiber(s) on the fiber core isaccomplished by controlling the number of complete overwrap-windingsallowed to occur per unit displacement of the fiber core away from thisorifice. If core displacement and overwrap rotation rates are held at apreset value, a helical winding as seen in FIG. 1 will result which willhave axial spacing dependent on the actual rates involved. If eithercore displacement or overwrap rotation rates are allowed to vary, muchmore complex axial repeat units, or geometries on the complexoverwrapped mandrel, can be generated. Under suitable conditions, norepeat units will exist. However, the resulting winding profile will bereproducible as long as the same rotation-rate patterns are employed. Itis also possible to allow the fiber core to reverse direction; i.e.,draw it back into the constraining orifice. This will result inover-winding of the overlap fibers on themselves.

In utilizing winding to make complex mandrels, there are numerous waysof actually winding overwrapping fibers over the fiber core. One type ofwinding apparatus 16, depicted in FIGS. 2, 3, and 4, has beenconstructed and used to make complex overwrapped mandrels which, aftercoating and core or mandrel removal, produced microbellows,microsprings, and microscrews, among other products. The windingapparatus 16 consists of two rotating gripping vises 18, whose motion iscoordinated by a sliding actuator 20. This actuator 20 consists of onenoncircular tube 22 shaped to smoothly fit inside anothersimilarly-shaped tube 24, both mounted in drive wheels 26 and 28,causing rotation of each vise. This synchronizes rotary motion of bothvises, yet permits linear translation of the second, or “locking” vise30, that holds and pulls the accompanying fiber core. The other vise, or“pull-through” vise 32 does not translate linearly. Spring-loaded jaws33, shown in FIG. 3, centrally located in each vise have adjustablescrew mechanisms. These jaws allow the locking vise to hold the fibercore tightly, completely preventing any slippage. Simultaneously, jawsin the pull-through vise are able to grasp the fiber core with justenough force to ensure rotary motion precisely in step with the vises,yet gentle enough to allow smooth fiber pull-through without elongation.FIGS. 3 and 4 illustrate the overwrap positioning device 34 which ispositioned closely to the pull-through vise 32. It consists of a slottedguide 36 which feeds overwrap fibers 10 over a pulley 35 to the rotatingfiber core 12 using the weight of the fiber and an additional weight 38attached to the overwrap fiber 10 as a tensioning mechanism. Thepositioning-device spacing 37 must be close enough to the pull-throughvise to eliminate twisting of the fiber core in the direction of appliedoverwrap torque. This also requires careful balancing of overwraptensioning weight. Too little weight, and overwrap fibers will not windtightly leaving gaps. Too much weight, and the fiber core will twist nomatter what positioner spacing is used. When constraining forcessupplied by the vise jaws are removed at the end of overwrapping, anyunwinding resulting from the fiber core twisting will destroy thefabricated micro-mandrel.

In fabricating complex overwrapped mandrels with theprecision-controlled adjustable-torque micro-winder, the core andoverwrap fibers can be but do not have to be of the same material, samecross-sectional shape or dimension. For some applications it isdesirable that at least one fiber or microscopic object of high aspectratio in the core be coated with at least one coating before overwrapping the at least one threadlike component. In addition, the one ormore overwrap threadlike components can also be coated with at least onesuitable material either prior to winding or after winding to increasetheir bonding to the fiber core, to fill in gaps and/or crevassesbetween fibers, or for special microtube manufacture. It is alsopossible to melt the surface of the one or more overwrap threadlikecomponents prior to winding over the fiber core so that their positionis secured by a melt-bond.

Once the complex overwrapped mandrel has been fabricated, it can becoated with at least one layer of material and then the mandrel can beremoved by a process that does not adversely affect the one or morecoatings. The result is a microtube device with variable axial geometry.

As with all the processes discussed in this application there arenumerous variations to the basic process just described. For example, acoated complex mandrel can be overwrapped with at least one threadlikecomponent to increase the wall strength of the device. This overwrappedthreadlike component, which can be bonded to the mandrel coating, couldthen have at least one additional coating deposited on top of it ifdesired. (Alternatively, of course the overwrapped at least onethreadlike component could be coated before it was wrapped.) If theoverwrapped threadlike component is then removed from the coating, amicrotube device with an overwrapped tube would result.

Another variation to the process just described produces a microtubewith a complex wall. In this case, instead of overwrapping an un-coatedcore forming a complex mandrel and then coating it, a core consisting ofat least one fiber or microscopic object of high aspect ratio of lengthto diameter is coated with at least one coating not adversely affectedby the conditions needed for the removal of the core. This coated coreis then overwrapped with at least one fiber or at least one threadlikecomponent either in a single or multiple passes to produce a wrapped orbraided coated-core. Another coating that is not adversely affected bythe removal of the core is applied on top of the overwrappedcoated-core. When the core is removed, a microtube with a complex wallis produced. Of course, this process of overwrapping and coated can berepeated as many times as needed for the particular application. Withthe fiber or threadlike component remaining in the wall, a microtubewith a reinforced wall is produced. If the fiber or threadlike componentin the wall is subsequently removed by a process that does not adverselyaffect the coatings, a central microtube with another microtube wrappedaround it is produced. This same device could also be produced byoverwrapping the core with a threadlike component that had previouslybeen coated.

A variation of the process to fabricate a microtube with a reinforcedwall involves coating the core with a thick coating and then embeddingthe overwrapped fiber in this coating. This can be accomplished inseveral ways such as using a hot wire as the overwrapping fiber or bysoftening the coating before overwrapping.

A final variation of the overwrapping of a threadlike component around acore to be mentioned involves the size of the core. In addition to themicroscopic cores mentioned thus far in connection with theprecision-controlled adjustable-torque micro-winder, it is also possibleto overwrap an object larger than 1000 microns with a fiber orthread-like component, coated fiber or coated thread-like component, ora microtube using a more conventional winding machine. In addition, thislarger core can also be overwrapped with a complex mandrel, coatedcomplex mandrel, complex mandrel from which the core, or complexmandrel, and/or at least one coating has been removed, complexsequential mandrel, coated complex sequential mandrel, or a complexsequential mandrel described below from which the core, complexsequential mandrel, and/or at least one coating has been removed. Inthis variation, the larger core can be formed from a complex sequentialmandrel discussed below or could be any other object in the range of1000-25000 microns. The over-wrapped core is called a complexoverwrapped macro-mandrel and a microtube device with at least oneinternal dimension less than 1000 microns that has been formed from acomplex overwrapped macro-mandrel is called a macro-sized microtubedevice. After overwrapping the core, it can be removed or remain.Subsequent processing may involve additional coating and removal cyclesas required for the particular device.

Obviously, in overwrapping a threadlike component around a core, thereare only two degrees of freedom that are needed. The core must translateand rotate with respect to the feed position of the at least oneoverwrapping threadlike component. This can be accomplished as in thepresent example by both translating and rotating the core. Equivalentcomplex mandrels can also be fabricated by rotating the core andtranslating the overwrapping positioning device 34 along the axis of thecore, translating the core and rotating the overwrapping positioningdevice 34 or by both rotating and translating the overwrappingpositioning device 34 with respect to the core. However, no matter howthe threadlike component is overwrapped around the core, the types ofcomplex mandrels that can be formed are limited by the fact that anoverwrapping threadlike component is being used which by necessity is acontinuous process around each core.

There are many other techniques discussed below that are able to addmaterial to, remove material from, or move material on a fiber core ineither a continuous or a non-continuous manner and thus are able toproduce additional types of complex geometries. These other techniquesrequire the use of a multi-axis complex microtube mandrel fabricationdevice with micron, or even sub-micron, positioning capability. Thisdevice, which in one configuration is essentially a more versatile andsophisticated form of the precision-controlled adjustable-torquemicro-winder described above, can take a multitude of forms. Basicallyit is comprised of a head that takes the place of the overwrappingpositioning device 34. This head is able to continuously ornon-continuously add material to, remove material from, change materialon, or move material on a fiber core, which is held straight in afixture. Like the precision-controlled adjustable-torque micro-winderthere must be relative translational and rotational motion between thehead and the fiber core. (This can obviously be accomplished in manyways as described above but for the purpose of the examples that followit is assumed that the fiber core will both rotate and translate withrespect to a stationary head.) In addition, for some techniques, thereneeds to be additional degrees of freedom for alignment of the head withrespect to the fiber core. Thus, there needs to be the ability in manyapplications to move the head orthogonally in up to three dimensionswith respect to the fiber core so that material is added, removed,changed or moved at the right position on the fiber core. In mostapplications the head is aligned perpendicular to the fiber core axisbut for some applications tilt of the head with respect to the fibercore axis will also be needed so that material is added or removed atthe desired angle to the fiber core.

Complex mandrels formed by adding material to the fiber core are calledcomplex augmented mandrels. These mandrels are formed by putting a fibercore composed of at least one fiber in a multi-axis complex microtubemandrel fabrication device and then placing at least one type ofmaterial with a predetermined cross-sectional shape on the fiber core inat least one predetermined location on the periphery of the fiber core.The placement of material can be either in a continuous ornon-continuous manner. In addition, more than one pass, with the same ordifferent material, can be made at each location on the surface of thefiber core so that the desired thickness of material can be placed.Thus, it is possible not only to control the position of materialplacement on the surface but also the type or types of material at eachlocation on the periphery of the fiber core.

Once the desired complex mandrel has been formed it is coated with atleast one layer of material producing a coated complex augmentedmandrel. If it is desired to produce a microtube device with theinterior shape of the complex mandrel, the coating or coatings shouldnot be removed by the process used to remove the complex augmentedmandrel after it has been coated.

A technology capable of forming complex mandrel geometries by addingmaterial to the fiber core is melt extrusion. In this technique materialis melt extruded directly onto the core in a circumferential and/oraxial manner. The head of the multi-axis complex microtube mandrelfabrication device for this technique consists of a very small diameterorifice or microscopic tube connected to a reservoir of molten materialunder pressure. For purely circumferential melt placement, translationof the core is halted but its rotation is continued. In contrast, forpurely axial melt placement on the core, rotation is halted, buttranslation allowed to continue. It should be noted that there arenumerous combinations of these two elementary processes in conjunctionwith the ability to control the flow of molten material, which can beused to produce complex mandrels with either uniform or randomgeometries after the viscous molten material has solidified. Also, itshould be mentioned that with this technique, as with all the othersdescribed in this application, complex mandrels formed in this manner,in addition to being coated to form devices after the complex mandrel isremoved, can also be used as the core (either coated or uncoated) insubsequent processing. In this manner, a vast number of non-circularcore-fiber cross-sections can be fashioned from either a circular ornon-circular fiber core in a sequential process. These melt-processednon-circular core-fiber segments can be interspersed at will betweeneither repeat wound segments or other repeat melt-processed non-circularcore-fiber segments with different geometry. It is also possible to makea microtube mandrel with this technique that has no repeat units, only ageometry that varies both circumferentially and/or cross-sectionally ina predetermined fashion.

A variation of the melt extrusion process to form a complex augmentedmandrel with the desired topography is to selectively place a viscousliquid of desired cross-sectional shape, such as a monomer or polymer,on the surface of the core in any desired manner. After the viscousliquid is placed on the surface at the desired positions, it can bedried if necessary by removing any solvent. If it is a monomer orpolymer, curing or polymerization of the monomer or furthercross-linking of the polymer using, for example, an energetic particlebeam (for example, electrons), temperature or radiation can be performedto produce a solid rigid topography on the surface of the core.

A vapor-phase process for forming complex augmented mandrel geometriesis also useful. Techniques such as plasma spraying either throughappropriate “masks” or using microscopic nozzles can be employed toplace deposited material on the core. Other types of chemical orphysical vapor deposition, such as, magnetron sputtering can also beemployed using a masking technique to selectively deposit one or morematerial on the surface.

A second class of technologies useful for forming complex mandrelgeometries is conceptually the opposite of the previous mandrel-formingtechniques discussed, in that rather than adding material in order toform a particular geometry on the core surface, it selectively removesmaterial from a core or core coating, either in a circumferential and/oraxial manner to produce a complex reduced mandrel. A rotating and/ortranslating core or coated core held in a multi-axis complex microtubemandrel fabrication device can have material “trimmed” either by energy(i.e., electron, ion, laser) beam ablation or other non-contacthigh-energy-delivery process (EDM for example), by particulate impactsuch as with a micron or sub-micron-sized particulate (sand, siliconcarbide, alumina, etc.), or by using heat, such as in the form of amicro-heatgun with a microscopic tube or orifice, or a hot wire. Allthese ablation techniques can be performed using either a focused beamof particulates, energetic particles, ions, or radiation by themselvesor in conjunction with a mask between the core and a source ofparticulates, energetic particles, heat, ions, or radiation. Byappropriately controlling core rotation and translation, as well aslocation of the ablating beam or heatgun relative to core axis, any ofthe complex mandrel geometries obtained with material depositionprocesses discussed previously as well as other geometries can beproduced.

Alternatively, at least one fiber in the core can be coated, for exampleby dipping or spraying followed by rotation about the fiber axis to evenout the coating as it solidifies if this is desired. It is then possibleto selectively remove some or all of this material at precise locationson the fiber core periphery. It is certainly possible to selectivelyremove some of this coating using the techniques just described.However, another preferred embodiment is to coat at least one fiber inthe core with a material such as photoresist (either positive ornegative). After coating, the fiber is exposed to radiation or aparticle energy source that will develop some of the photoresist andproduce the desired topology on the surface of the fiber after some orall of this exposed material or the unexposed material at preciselocations on the fiber core periphery is selectively removed, forexample, by solvation or plasma. This exposure of the photoresist can beperformed through a mask as is traditionally done in 2-D lithography orit can be done using a focused radiation or particle source incombination with relative motion between the fiber and the radiation orparticle source. In one application, the head of the complex microtubemandrel fabrication device would consist of either a focused radiationor particle source and in the other application it would hold the mask.Obviously, for these applications in addition to the need for the headto be aligned relative to a position on the core, it is also necessaryto be able to control the distance between the head and the core inorder to properly focus the energy on the surface to produce a highquality complex reduced mandrel. As stated previously, to make amicrotube device from the reduced mandrels, it is necessary to coat themandrel with at least one layer of material that is not removed by theprocess used to remove the mandrel. This is called a coated complexreduced mandrel. Thus, when the mandrel is removed from the coating, amicrotube device is formed.

Finally, in addition to depositing material on or removing material fromthe fiber core or a fiber core coating, the desired topology on theperiphery of a core or coated core can be obtained by using techniquesthat move or redistribute material on the surface of the core or coatedcore to produce a complex redistributed mandrel. This movement ofmaterial occurs in either a continuous or non-continuous manner in atleast one pre-determined location on the periphery of the core. Inaddition, more than one pass can be made at each location on the surfaceof the core so that the desired thickness of material can beredistributed.

The movement of material on the periphery of the core can beaccomplished in many ways such as embossing using pressure either in amold or a press, embossing with heat such as with a hot wire or heatsource in combination with a tool used for pushing or pulling material,or by selectively crimping portions of the surface.

Five different means to form a complex mandrel (adding material to,removing material from, moving material on, changing the radialdimensions of, or wrapping around a core) have just been described. Eachof these individual processes is able to produce a complex mandrel thatcan be coated and then removed producing a microtube device. However, itis also possible to use these complex mandrel fabrication techniques insequence to produce even more elaborate complex mandrels called “complexsequential mandrels” that can not be produced in any other way. Thissequential processing, which can involve any combination of processingin any order, is a 3-dimensional analog to commercial silicon wafertechnology where there are many sequential steps to produce complexstructures with many layers.

Thus, any product of one of the five complex microtube fabricationtechniques which we call a “previously fabricated component” can be usedas the core for subsequent processing with the same or a differentprocess. Alternatively, they can be used as the overwrapping threadlikecomponent in fabricating a complex sequential overwrapped mandrel. Thesepreviously fabricated components can be complex mandrels, complexmandrels that have been coated, or coated complex mandrels from whichthe core, or complex mandrel, and/or at least one coating has beenremoved. Thus, any product of a previous process can be used as a coreor overwrapping threadlike component in one or more subsequentprocesses, which may be a different process or a repeat of the sameprocess.

Since these complex sequential mandrels cab be formed in a number ofways it is convenient to name them by the last technique performed onthem. Thus, for the sake of clarity, a core composed of at least onepreviously fabricated component that has material added to the core iscalled a complex augmented sequential mandrel. If material is removedfrom the core composed of at least one previously fabricated component,the result is a complex reduced sequential mandrel. If material is movedon the surface of the core composed of at least one previouslyfabricated component, the result is a complex redistributed sequentialmandrel. Finally, if the core or the overwrapped threadlike component iscomposed of at least one previously fabricated component, the mandrel iscalled a complex overwrapped sequential mandrel. Obviously, thissequential processing can go through many cycles with the product of aprevious process becoming the core or the overwrapped thread-likecomponent of the present process.

As has been stated, in all the different techniques described in thispresent application that are used to produce a complex mandrel, eitherthe core is moved relative to the head or the head is moved relative tothe core. Obviously, numerous different types of complex microtubemandrel fabrication devices can be constructed so that any of therelative motions is possible. However, using the micro-winder previouslydescribed, it is only possible to rotate and translate the fiber corerelative to the stationary head.

FIG. 5 illustrates how the basic winding apparatus depicted in FIGS. 2,3, and 4 can be modified to enable melt or solution-processing,vapor-processing, ablation-processing and some forms of materialmovement to be performed. Essentially all that needs to be done is toreplace the positioner 34 and accompanying overwrap fiber and overwrapweight with new devices capable of carrying out each particular mode ofprocessing. For melt or solution-processing, a miniature polymerextruder similar in concept to a hot hypodermic syringe 40 deliversmolten or solvated periphery modification material 41 to the rotatingtranslating core fiber 12. For vapor-processing, a miniature plasmaspray torch delivers periphery modification material material. And forablation-processing, a suitable high-energy delivery system such as aradiative or particle beam 42 can be positioned in such a fashion thatit “trims” unwanted material 43 from the rotating translating fiber core12. In some applications, the high energy delivery system can bepositioned to impact the unwanted material head-on, thereby cutting theunwanted material or the boundaries of the unwanted material at a highrate to facilitate removal. Alternatively, the head-on impact of thebeam can be employed to modify the fiber core 12, for example, by makingdepressions or trenches in a solid core or by making holes or slits in ahollow core.

Although these processes are quite different from overwrap fiberwinding, they too must be designed so that tensions and stresses,thermal as well as mechanical, induced by each type of process arecarefully controlled- otherwise unacceptable distortion of the mandrelwill take place either upon release from the basic winding apparatus orupon subsequent processing. As mentioned previously, thisprecision-controlled adjustable-torque micro-winder and its accompanyingtechnology differs fundamentally from similar, but macroscopic,applications. Forces and effects usually considered negligible inmacroscopic terms become over-riding at the micron level. For example,overwrap stress-strain properties are inconsequential in macroscopicwinding applications. At the micron level, however, stress-strainbehavior cannot be so easily dismissed. It is integral to successfulfabrication.

The most straightforward devices capable of being manufactured with thisprocess are bellows, springs, screws, heat exchangers, and 3-dimensionalobjects of revolution having dimensions on the micron level. Utilizationof such miniature mechanical apparatus requires considerable innovationon the part of design engineers. Downsized applications range fromflexible electrical connectors for micro-circuitry to novel new sensorsutilizing microspring or microbellows displacements as a means ofmeasuring applied force.

EXAMPLE 1

The simplest winding pattern is that of a helix 14, FIG. 1; i.e., acircular overwrap threadlike component 10 of diameter “c” wound around acircular core 12 of diameter “b”, with a spacing of “a”. The winding canbe either right-handed or left-handed helix 14, and spacing can varyfrom a minimum of “a” equal to “c” to “a” approaching infinity. Both thecore and the overwrapping threadlike component can be either amicroscopic object of high aspect ratio or a fiber with across-sectional dimension in the range of 1-1000 microns. For thepurposes of this example they are both assumed to be fibers.

If an overwrapped fiber is wound around a fiber core of unrelatedmaterials that utilizes removal methods that have no adverse effect onthe overwrapped fiber, then when the fiber core is removed, a coiledfiber will result. The method of removal of the fiber core in thisexample, which can for example be by reaction, solvation, vaporization,phase change, or simply pulling it out, is irrelevant to the formationof the coil. Once the coil is formed and free-standing, it is coatedwith the desired material. Of course, it is equally possible to coat theoverwrapping fiber or threadlike component before it is wrapped aroundthe core. If the coated overwrapped fiber is not removed from thecoating, a composite coil is produced. as seen in FIG. 6. If the coatedwrapped fiber is removed from the coating, a microtube coil is producedFIG. 7. These hollow coils can be used as a flexible coupling inmicrofluidic devices, a force or pressure sensor, or in electrical ormagnetic applications such as a microscopic solenoid, transformer, orpickup coil. In these applications there is the possibility of coolantflowing through the center of the hollow coils to remove heat.

If more than one layer of coils is required, such as in some solenoidand transformer applications, the overwrapped fiber can be wound back onitself as described above. Of course, for electrical applications suchas these, the coil layers need to be insulated from one another. Thiscan be accomplished by depositing a layer of insulation between the coillayers. Alternatively, one can wind either a conductive fiber with aninsulating layer or a fiber that has an inner conductive layer and anouter insulative layer. Obviously, the conductive fiber would not beremoved while the fiber with the two coatings could be removed.

The coil formed by this technology can also function as a spring and beused as a force or pressure sensor. This coil spring can be eitherhollow or filled. The spring constant can be controlled by varying thediameter of the coil, the diameter of the coated fiber, the spacing ofthe coils, the material of the fiber coating, the thickness of thecoating, and whether the overwrapped fiber is removed or not.

If the fiber core diameter and overwrap fiber spacing are considerablylarger than overwrap fiber diameter, the microtube resulting aftercoating both the overwrapped and the fiber core together and thenremoving both fibers will resemble a microbellows 46, FIG. 8A. Aphotograph of a bellows fabricated by this technique is shown in FIG.8B. Of course, this bellows could also be manufactured by the othermeans discussed above. For example, material could be added to the coreto form the fins, material could be removed from the core to form thedepressions between the fins, or a technique such as embossing with ahot wire could be used. Obviously, for this simple structure many othertechniques could also be employed.

There are numerous variations to the simple procedure of winding,coating, and fiber removal. Three such variations involve changing thecore or overwrapped fiber cross-sectional-shape, coating sequences, andmethod of overwrapping are given below.

A variation of the helical winding pattern mentioned above is to employnoncircular overwrap fibers and/or a noncircular fiber core. For examplein FIG. 9, if a trilobal overwrap fiber 48 is wound tightly enougharound a circular fiber core 12, the trilobal fiber will deform into theshape of a “T”. By spacing the “T” overwraps such that there are no gapsin between, a threaded screw 50 is precisely formed. It can have eitherright-handed or left-handed thread. Depending on the application, coreand overwrap fibers may or may not be removed after coating. In the caseof a screw they would probably be retained whereas in the case of abellows they would be removed as with most examples discussed, thisscrew mandrel can also be fabricated in a number of ways. For example, arectangular bead of material could be continuously extruded onto thefiber core surface or material could be removed from the periphery ofthe fiber core to produce rectangular depressions.

EXAMPLE 2

In addition to changing the cross-sectional shape of the overwrappingfiber it is also possible to coat the fiber core 12 (FIG. 10A) with alayer 52 before wrapping it with one or more overwrap fibers 10, andthen coating it again with a second layer 54. Once the fiber core 12 andall overwrap fibers 10 have been removed, a microtube device 56 isformed that consists of a hollow helical channel wound around a hollowcore tube. Such a device is presented in FIG. 10B. This process can berepeated to give as many layers of helical overwrap channels as desired.The two separate coating procedures and materials used do not have to bethe same, and more than one coating can be employed in each. Also,noncircular core and/or overwrap fibers can be employed providingcorrespondingly shaped-core tubes and/or helical overwrap channels. Anexample of this is to employ a threaded-screw microtube 50 as the fibercore, and then overwrap circular fibers in the screw threads. FIG. 11illustrates such a microtube device 58 once both core and overwrapcoatings have been applied, and both core and overwrap fibers have beenremoved.

Most chemical or mechanical engineers will readily identify FIGS. 10 and11 as heat exchangers, capable of being utilized in either co-currentflow or counter-current flow situations. For example, in FIG. 11 fluidwould flow in channel 60 and a second fluid could flow in the helicalchannel 62. An immediate application certainly exists in the cooling ofhigh-power-density electronic microcircuits. These or similarconfigurations of microtubes can also be employed as microreactors forchemical synthesis. Again, any of the other techniques used to depositmaterial on, remove material from, or move material on the periphery ofthe fiber core can be used to form these structures.

FIGS. 10 and 11 offer a good example of the versatility of the presenttechnology. That is, by making only minor changes in processing,completely different products can be fabricated. For example, in FIG. 10if only the fiber core is removed and not the overwrapping fiber, amicrotube with a reinforcement fiber in the wall will result. Obviously,more than one overwrapping pass can be made or multiple fibers can bewrapped producing a braiding in the tube wall.

EXAMPLE 3

If any technique discussed (ie. melt-processing, vapor-processing,embossing, ablation-processing, etc.) other than fiber overwrapping isemployed, an actual bellows can be fabricated; i.e., zero pitch isachieved by forming a completely circumferential fin, on the fiber coreat each repeat-unit location as seen in FIG. 12. (This is due to thefact that overwrapping by definition is a continuous process andtherefore can only produce a continuous spiral fin. All the othertechniques, in addition to being a continuous process, can also benon-continuous and thus only add, remove or move material in a purelycircumferential manner at different locations on the fiber coresurface.) This particular bellows was fabricated by selectively removingmaterial from the fiber core, coating the fiber core, and then removingthe fiber core. However, an equivalent structure can be produced by anytechnique that selectively adds material to the fiber core, selectivelyremoves material from a layer on the fiber core, or selectively movesmaterial such as embossing. The choice of techniques simply depends onthe materials desired, the complex geometry to be fabricated, the easeof fabrication and the cost.

With any of these techniques, it is possible to produce bellows of anyimaginable shape. FIG. 13 features two of the many possibilities. Shownare a square bellows (FIG. 13A) and a square bellows with a twist (FIG.13B). Also shown is a round bellows with a dovetailed end (FIG. 13C) forattaching the bellows to a dovetailed channel on a micro-device. Withthe detailed end mounted on the micro-device and then sealed, thebellows is able to transport relatively high pressure gases and liquids.

Thus, bellows formed by this invention can be used as flexible couplingsto carry gases or liquids between devices. A somewhat more sophisticatedapplication at the micron level utilizes two of the properties ofbellows; i.e., they are flexible and elongate under pressure 65 if oneend is sealed. In FIG. 14, the bellows 63 is inserted into a rigid tube64, bending is prevented and only one-dimensional motion is permitted.The resulting micro-actuator 66 is illustrated in FIG. 14. Obviously, anactuator utilizing micro-bellows can have as many degrees of freedom asthere are bellows in the actuator and, in addition, the motion of thesebellows can be nonlinear as a function of driving force. Many other usesfor such a device can be envisioned. For example, the bellows sealed onone end and inserted in a rigid tube can also be used as a piston in avalve or pump. Even with clearance between the piston and the wall andwithout a ring or seal, this piston can be used to pump a non-wettingfluid. If it is desired to pump a fluid that wets the walls of the tube,a non-wetting droplet can be used as a seal according to PatentApplication AFB 394. A micro-valve 68 in the half-open position isillustrated in FIG. 15.

If two or more bellows are attached together carefully at appropriateintervals 72 into a microbellows-assembly 70 as seen in FIG. 16A,applying a higher pressure 67 to one of them more than the others (FIG.16B) will cause the remaining bellows in the assembly to deform in adirection away from the pressurized bellows. A similar response can beachieved by causing one bellows to shrink. In fact, a similar bendingmotion can also be achieved with only a single bellows. In this case, abellows is fabricated so that over a significant length of the bellowsthere are smaller ribs 76 (or no ribs) on one segment of the peripheryaligned along the axis (FIGS. 17A, 17B and 17C). If this “single finger”bellows 78 is then pressurized, it will bend toward the side that hasthe smaller ribs. For each of these designs, the overall effect can bethought of as similar to bending one's forefinger. A slight variation ofthe “single finger” bellows is to have the smaller rib section curvearound the axis of the bellows instead of being linear along the axis.In this case the bellows will twist as well as bend. Obviously, therelative portion of twisting motion vs bending motion will be controlledby the pitch of the smaller ribs along the axis of the bellows.

Putting together two or more of these “micro-fingers” will result in a“micro-hand” which provides for manipulation at the micron level.Moreover, pressurizing or otherwise activating more than one bellows inan assembly will cause the entire assemble to change length as well asbend. By appropriately mounting microbellows-assemblies together,three-dimensional manipulation over relatively large distances at themicron level becomes feasible. Applications for these manipulatorsinclude positioning and working with specimens under microscopes,fabricating and/or repairing micro-electromechanical systems (MEMS), andmicrosurgery.

In any applications of the microbellows that is sealed on one or bothends, the elongation or contraction can take place in a number of ways.These include actuation using fluids inside the bellows (for example,hydrolytic, pneumatic, or electrokinetic actuation), as well as moreexotic techniques involving a change in the length of the bellowsmaterial or a material in contact with the bellows. Thus, if the bellowsis fabricated, for example, from a piezoelectric material, amagnetostrictive material, an electrostrictive material or ashape-memory alloy, the length can be changed by applying electrical,magnetic, or thermal energy. Obviously, the bellows need not be closedon either end to utilize these more exotic techniques.

It was stated in Example 1 that after the coil was coated, it waspossible to leave the coated-fiber core in place to strengthen the coil.Obviously this is different technology than has been described inprevious microtube patent applications. Microtube technology bydefinition forms a tube by removing a core consisting of a fiber ormicroscopic object of high aspect ratio from at least one coating placedon it. It should be noted that the process to remove the core can notadversely affect the at-least-one coating forming the tube wall.However, if the core is not removed or if one or more coatings areselectively removed leaving the core and at least one coating, anentirely new class of devices can result. For example,multi-layered-fiber coatings can be useful in the fabrication devicessuch as those that have an annular volume. This and many other devicescan be made by applying multiple coatings to a core, complex mandrel, orsequential complex mandrel and then selectively, partially orcompletely, removing some of the layers leaving behind other layers andeven, in some cases, the core, complex mandrel, or sequential complexmandrel. Of course, the core or complex mandrel can also be partially orcompletely removed.

By way of example, a fiber can be coated with two layers. If the layerclosest to the fiber is preferentially removed, a device with an annuluswould result with the annular volume contained between the originalfiber and the outer coating. Of course, there would need to be some sortof axial and/or circumferential rib structure on the fiber mandrel tosupport the outer coating and keep the annulus open. As in most devices,this can be accomplished in a number of ways. A few will be given.

EXAMPLE 5

A simple example of the fabrication of this type of device is to startwith an extruded fiber with ribs such as a trilobal fiber 80 in FIG.18A. Using a multi-axis fabrication device, material 82 of a differenttype than the fiber can be added axial along the fiber filling thevolume between the ribs. It should be noted that material 82 must beable to be removed by a process that does not remove the fiber 80. Thiscomplex augmented mandrel is then coated with another material 84different than the material between the ribs 82 and not removed by aprocess used to removed the material 82 between the ribs. When thematerial between the ribs 82 is removed (FIG. 18B) a structure 86 withan annular volume 88 results. If the fiber core 80 has first been coatedwith a conformal layer 90 (FIG. 18C) before the material 82 is placedbetween the ribs and the coating 84 has been applied, when the fibercore 80 and material 82 are removed, a device 92 (FIG. 18D) with acentral volume 94 as well as a concentric annulus 96 results. This tubewithin an annulus would prove useful in the fabrication of a counterflowheat exchanger or injectors, for example.

Obviously, there are numerous other ways to fabricate these annularstructures. For example, to form a structure such as the annularstructure 92, a rather thick coating 98 could be applied to a roundfiber 100 (FIG. 18E). (It is necessary that techniques used to removecoating 98 not affect fiber 100.) The coating 98 is then partiallyremoved or moved from locations 102 corresponding to the volumes betweenthe rib structures needed to support the annulus (FIG. 18F). A secondcoating 104, which is not affected by techniques to remove coating 98,is placed on top of coating 98 filling all voids (FIG. 18G). Whencoating 98 is completely removed, voids 106 (FIG. 18H) result formingthe annulus.

As should be apparent, a myriad of axial topographies on the micronscale leading to numerous micro-devices can be made using thisinvention. (A micro-rocket nozzle and a micro-camera bellows with a lensshade with interior dimensions of ˜200 microns are shown by way ofexample in FIGS. 19A, 19B and 19C). Using the various techniques to addmaterial to, subtract material from, move material on, modify the radialdimensions of, or wrap material around the core, either alone or incombination, results in very complex mandrels for the fabrication ofmicrotube devices. For example, using melt processing more than one beadcan be placed immediately next to another, or on top of another during asubsequent step of mandrel fabrication, to achieve whatever geometry isdesired. This complex mandrel can then be “machined” to produce even amore complex mandrel. If you add to these capabilities, the possibilityof starting with a mandrel of any cross-sectional shape, practically anycomplex-shaped mandrel can be fabricated.

Clearly, many modifications and variations of the present invention arepossible in light of the above teachings and it is therefore understood,that within the inventive scope of the inventive concept, the inventionmay be practiced otherwise then specifically claimed.

What is claimed is:
 1. A method of forming a microtube with a wallcontaining passages comprising: providing a core, placing at least onecoating on said core, forming a complex over-wrapped mandrel on amicro-winding device by over-wrapping at least one threadlike componentabout the coated core, coating said complex over-wrapped mandrel with atleast one layer of material to produce a coated complex mandrel andremoving said core and said over-wrapped threadlike component, toproduce a microtube containing wall passages.
 2. A method of forming amicrotube device a defined in claim 1 in which the core consists of atleast one microscopic object with a high aspect ratio of length todiameter or at least one fiber with a cross-sectional dimension in therange of about 1 to 1000 microns.
 3. A method of forming a microtubedevice as defined in claim 1 in which the at least one threadlikecomponent consists of at least one microscopic object with high aspectratio or at least one fiber with a cross-sectional dimension in therange of about 1 to 1000 microns.
 4. A method of forming a microtubedevice as defined in claim 1 further including depositing at least onecoating on said at least one overwrapping threadlike component beforeoverwrapping said at least one overwrapping threadlike component on saidcoated core.
 5. A method of forming a microtube device as defined inclaim 1 wherein said at least one overwrapping fiber is made ofpolyetherimide.
 6. A method of forming a microtube device as defined inclaim 1 in which the surface of said at least one overwrappingthreadlike component is melted just before being wrapped on said coatedcore to form a melt-bond with said coated core.
 7. A method of forming amicrotube device as defined in claim 1 in which the overwrappingthreadlike component is comprised of at least one previously fabricatedcomponent selected from the group consisting of a complex mandrel, acoated complex mandrel and a coated complex mandrel from which the core,or complex mandrel and/or at least one coating has been removed; saidpreviously fabricated component having been fabricated by processselected from the group consisting of changing the radial dimensions ofa fiber core, overwrapping a core, adding material to a fiber core,removing material from a fiber core, moving material on a fiber core anda combination thereof.
 8. A method of forming a microtube device asdefined in claim 1 further including overwrapping at least onethreadlike component on top of the coated complex overwrapped mandrel.9. A method of forming a microtube device as defined in claim 8including adding at least one additional coating on top of the at leastone threadlike component overwrapping the coated complex overwrappedmandrel.
 10. A method of forming a microtube device as defined in claim9 further including removing at least one threadlike component from itscoating after it has been overwrapped on top of the coated complexoverwrapped mandrel.
 11. A method for forming a macro-coil of a tubularthreadlike component comprising: providing a core and a threadlikecomponent, placing a coating on said threadlike component to form acoated threadlike component, forming a complex overwrapped macro-mandrelon a winding device by overwrapping at least one of said coatedthreadlike component about said core; removing said core from saidmacro-mandrel to produce at least one free-standing macro-coil of coatedthreadlike component and removing at least one threadlike component fromsaid coating to produce a macro-coil of tubular threadlike component.12. A method of forming a macro-coil of tubular threadlike component asdefined in claim 11 in which the core consists of an object with across-sectional dimension in the range of about 1,000-25,000 microns.13. A method of forming a macro-coil of tubular threadlike component asdefined in claim 11 in which the overwrapping threadlike componentconsists of a microscopic object with high aspect ratio or at least onefiber with a cross-sectional dimension in the range of 1-1000 microns.14. A method of forming a macro-coil of threadlike component as definedin claim 11 in which the overwrapping threadlike component is comprisedof at least one previously fabricated component selected from the groupconsisting of a complex mandrel, a coated complex mandrel, and a coatedcomplex mandrel from which the core or mandrel and/or at least onecoating has been removed; said previously fabricated component havingbeen fabricated by a process selected from the group consisting ofchanging the radial dimensions of a fiber core, overwrapping a core,adding material to a fiber core, removing material from a fiber core,moving material on a fiber core and a combination thereof.
 15. A methodof forming a macro-coil of tubular threadlike component comprising:providing a core and a threadlike component, forming a complexoverwrapped macro-mandrel on a winding device by overwrapping saidthreadlike component about said core; removing said core from saidmacro-mandrel to produce at least one free-standing macro-coil ofthreadlike component; placing a coating on the threadlike component andremoving said threadlike component from said coating to produce amacro-coil of tubular threadlike component.
 16. A method of forming amacro-coil of threadlike component as defined in claim 15 in which thecore consists of an object with a cross-sectional dimension in the rangeof about 1000-25,000 microns.
 17. A method of forming a macro-coil ofthreadlike component as defined in claim 15 in which the overwrappingthreadlike component consists of a microscopic object with high aspectratio or at least one fiber with a cross-sectional dimension in therange of 1-1000 microns.
 18. A method of forming a macro-coil ofthreadlike component as defined in claim 15 in which the overwrappingthreadlike component is comprised of at least one previously fabricatedcomponent selected from the group consisting of a complex mandrel, acoated complex mandrel, and a coated complex mandrel from which the coreor. mandrel and/or at least one coating has been removed; saidpreviously fabricated component having been fabricated by a processselected from the group consisting of changing the radial dimensions ofa fiber core, overwrapping a core, adding material to a fiber core,removing material from a fiber core, moving material on a fiber core anda combination thereof.